117. O-LEVEL MMCOPage 1 of 50

117. ORGANIZATIONAL LEVEL (O-LEVEL) MAINTENANCE MATERIALCONTROL OFFICER FUNDAMENTALS

References:

[a] OPNAVINST 4790.2H, Naval Aviation Maintenance Program (NAMP), Vol. I

[b] OPNAVINST 4790.2H, Naval Aviation Maintenance Program (NAMP), Vol. II

[c] OPNAVINST 4790.2H, Naval Aviation Maintenance Program (NAMP), Vol. III

[d] OPNAVINST 4790.2H, Naval Aviation Maintenance Program (NAMP), Vol. V

[e] OPNAVINST 5442.2G, Aircraft Inventory Reporting System

[f] OPNAVINST 4440.25, Consolidated Remain-In-Place List (CRIPL) for

AviationMaterial

[g] NAVAIRINST 13700.15C, Aircraft Engine Management System

[h] COMNAVAIRPACINST 4790.42, Procedures for Requesting Planner and

Estimator(P&E) Services

[i] OPNAVINST 5442.4M, Aircraft Material Condition Definitions, Mission-

EssentialSubsystem Matrices (MESM) and Mission Descriptions

[j] NAVAIR 01-1A-34, Aeronautical Equipment Welding

[k] NAVAIR 01-1A-16, Nondestructive Inspection Methods

[l] Local Directives and Standard Operating Procedures

[m] COMNAVAIRPAC/COMNAVAIRLANT INST 5442.5D, Aircraft Material Readiness

Reporting

[n] COMNAVAIRFORINST 4790.46, Aircraft Carrier (CV/CVN)/Carrier Air Wing

(CVW)Aviation Support Phased Milestone Program

.1 Discuss the purpose of and information contained in an ADB. [ref. c, ch. 5]

* Maintenance Control will maintain an ADB for each aircraft assigned. The ADB is designed to provide maintenance and aircrew personnel with an accurate, comprehensive, and chronological record of flights and maintenance performed on a specific aircraft by BUNO for at least the last 10 flights. All aircrew, ground crew, and fix phase MESM coded discrepancies, as well as all other outstanding fix phase discrepancies, shall be displayed in the ADB so the aircrew is fully aware of potential limitations for a safe and successful mission. For phase or special inspections, only the control document representing all look phase actions needs to be displayed in the ADB. The ADB shall accurately reflect the status of all pending maintenance requirements as displayed in the NALCOMIS data base, the Maintenance Control Supervisor will verify the ADBs with NALCOMIS at least daily. The ADB for each specific BUNO shall be screened for accuracy of completed and outstanding MAFs before Maintenance Control certifies the aircraft safe-for-flight.

NOTES: 1. When a special inspection is completed, the control document will be retained in the ADB for 10 subsequent flights or until completion of the next like special inspection

2. Equipment Discrepancy Books for AMCM equipment will be maintained by the AMCM Systems Maintenance Department Maintenance Control using the instructions for ADBs.

.2 Discuss the following inspections: [ref. a, ch. 12]

  1. Daily/turnaround

1. Daily inspection is conducted to inspect for defects to a greater depth than the turnaround inspection. The daily inspection is valid for a period of 72 hours commencing from the date and time the inspection is completed, provided no flight occurs during this period and no maintenance other than servicing has been performed. Aircraft may be flown for 24 hours without another daily. This 24 hour period begins with the first launch following accomplishment of the daily inspection. The 24 hours cannot exceed the 72 hour expiration of the daily unless the expiration occurs during a mission. In this case the aircraft will require a daily before the next flight. Turnaround requirements are not included in the daily inspection and must be accomplished separately. Accomplishment of a turnaround does not affect the 72 hour validity of the daily inspections. See 4790 VOLI.(Figure 12-3).

NOTES: In the event maintenance, other than servicing, must be performed after the daily inspection or turnaround inspection, Maintenance Control shall determine if a complete daily or turnaround inspection or portion thereof is required. 2. COs may authorize pilots-in-command to conduct applicable T/M/S NATOPS pilot inspection, ensuring servicing requirements are accomplished, and sign the Aircraft Inspection and Acceptance Record (OPNAV 4790/141) in the certification block while operating away from home without qualified maintenance personnel for periods not exceeding 72 hours. Accomplishing these requirements, rather than completing all daily, turnaround, and fuel sampling requirements, is sufficient for safe for flight certification.

2. Turnaround Inspection is conducted between flights to ensure the integrity of the aircraft for flight, verify proper servicing, and to detect degradation that may have occurred during the previous flight. The turnaround inspection may be considered valid for a period of 24 hours commencing from the date and time the inspection is completed, provided that no flight and no maintenance other than servicing occurs during this period. The accomplishment of the daily inspection does not satisfy the turnaround inspection requirements.

NOTE: Accomplishment of a complete turnaround inspection is not required between repetitive flight evolutions interspersed with ground periods, such as passenger or cargo stops, hot seating, hot refueling, or short interruptions for adjustments during helicopter FCFs. Accomplishment of a turnaround inspection is not required if cold refueling T-34C/T-44A/T-6A Training Command aircraft between flight evolutions when the pilot in command remains the same. All applicable NATOPS checklists shall be complied with during ground periods. When servicing or other minor maintenance is performed during such ground periods, only those portions of turnaround inspections applicable to that servicing or maintenance need to be performed, as directed by Maintenance Control. This is not intended to limit commands from exercising their prerogative of performing inspections they deem necessary. Inspection or servicing intervals shall not be exceeded during successive evolutions.

b. Phase: The phase maintenance concept divides the total scheduled maintenance requirement into small packages or phases of approximately the same work content. These are done sequentially at specified intervals. Completion of all required phases at their specified intervals completes the phase inspection cycle. The cycle is repetitive for the service life of the aircraft and is not interrupted during standard or special rework. Phase inspections are not included in the standard rework specifications, and are not done during the standard or special rework process. Aircraft returning from standard or special rework have the next phase due upon expiration of the authorized interval from the last phase inspection completed.

c. Special: This inspection is a scheduled inspection with a prescribed interval other than daily or phase. The intervals are specified in the applicable PMS publication and are based on elapsed calendar time, flight hours, operating hours, or number of cycles or events, for example, 7, 28 days; 50, 100, 200 hours; 10, 100 arrestments; or 5,000 rounds fired. In some cases, aircraft special inspections contain within them engine inspection requirements. They are referred to as combined airframe and engine specialinspections. All engine inspections, except fluid sampling, engine wash, recurring special engine inspections not requiring NDI or disassembly/reassembly, or servicing, require AESR entries or CM ALS updates. All other equipment having an AESR require entries only if the inspection requires NDI or disassembly and reassembly. Refer to the logbook Inspection Record section. Inspections base-lined in the CM task will be automatically logged in the appropriate CM ALS inspection record for activities with NTCSS Optimized OMA NALCOMIS. Corrosion inspections may be a part of the daily/servicing/special MRCs or may be produced locally as corrosion control decks.

(a)Completed aircraft special inspection MAFs or WO( Work Order)s shall be maintained in the aircraft inspection file or the electronic historical files.

(b) There are cases where a special inspection or group of special inspections, which because of their intervals become due simultaneously, may consume more than 8 hours of elapsed maintenance time. When the condition has an adverse affect on aircraft availability, they may be divided with portions being performed incrementally any time during the allowable deviation period. When the above deviation is used, Maintenance Control or Work Center 140 must maintain the controlling special inspection MAFs or WO for each inspection performed. Work centers will be issued MAFs or WOs listing the applicable MRCs for that portion of the inspection to be completed. The listing of applicable MRCs on the WO is not required for activities with NTCSS Optimized OMA NALCOMIS. The above procedure will ensure that when work centers sign off their supporting special inspection MAF or WO the applicable section of that inspection has been completed and a QAR or CDI inspection has been performed.

NOTE: Organizational activities maintaining helicopter dynamic components requiring an AESR are not required to log repetitive NDI inspections based on less than 100 hour intervals. When aircraft are transferred or AESR tracked components are removed/cannibalized, activities shall log the most recent NDI inspections (each type and interval) performed and component hours (not required for activities with NTCSS Optimized OMA NALCOMIS; all inspections are electronically logged upon completion of a WO that affects CM ALS.

d. Conditional: Conditional maintenance requirements are unscheduled events required as the result of a specific over-limit condition, or as a result of circumstances or events which create an administrative requirement for an inspection. A logbook or CM ALS entry is required for a conditional maintenance requirement which prescribes inspections to determine equipment condition, for example, airframe hard landing, pre-carrier, pre-deployment, aircraft ferry, acceptance, transfer, and engine overspeed and overtemp inspections. Those conditional requirements which specify servicing or fluid sampling need not be logged.

e. Acceptance/transfer

1. Acceptance Inspectionis performed at the time a reporting custodian accepts a newly assigned aircraft, from any source, including return of an aircraft from an off-sight depot facility. It includes an inventory of all equipment listed in the AIR, verification of CADs and PADs, a configuration verification, hydraulic fluid sampling, a daily inspection, and a complete FCF. For acceptance inspectionpurposes, verification of CADs, PADs, and configuration is accomplished by visual external inspection and record examination only. Disassembly beyond daily inspection requirements of applicable PMS publications is not required. Verify flight hours are correct on the Monthly Flight Summary (OPNAV 4790/21A) by checking the Period and Since New blocks. In addition, verify correct operating hours on the Equipment Operating Record (OPNAV 4790/31A) by checking the ACCUM block. Activities may elect to increase the depth of inspection if equipment condition, visual external inspection, or record examination indicates such action is warranted. On acceptance of an aircraft, load the SEATS/ICAPS module data disk received with the aircraft logbook. The FCF requirement may be waived by the ACC/TYCOM for intra-wing transfers providing all of the following conditions are met:

NOTE: Activities deploying detachments, for example, HC or HSL, that transfer and accept aircraft between homeguard and detachment are not required to perform a physical transfer inspection or acceptance inspection and FCF. The administrative requirements, for example, configuration and AIR verification, OPNAV XRAY, and ETRs are still required.

(a) Following mutual agreement of both reporting custodians, candidate aircraft shall be identified by the Wing/MAW to the ACC/TYCOM via naval message for FCF waiver.

(b) Aircraft will have flown a mission or training flight within 10 days prior to transfer.

(c) Aircraft will be in AXX-XXO status at the time of transfer.

(d) Aircraft will be in FMC condition at time of transfer.

(e) Each waiver request shall be approved or disapproved by the ACC/TYCOM via naval message, separate from the ATO/ATL. Waiver authority cannot be delegated.

(f) Final waiver approval will not preclude either reporting custodian from conducting a FCF any time as prerequisite to custody changes.

(g) Aircraft will meet all other acceptance inspection requirements.

2. Transfer Inspectionis performed at the time a reporting custodian transfers an aircraft to another operating activity including a delivery to an off-site depot facility. It includes an inventory of all equipment listed in the AIR, verification of CADs and PADs, a configuration verification, and a daily inspection. For transfer inspection purposes, verification of CADs, PADs, and configuration is accomplished by visual external inspection and record examination only. Disassembly beyond daily inspection requirements of applicable PMS publications is not required. Verify flight hours are correct on the Monthly Flight Summary Form (OPNAV 4790/21A) by checking the Period and Since New blocks. In addition, verify operating hours on the Equipment Operating Record (OPNAV 4790/31A) by checking the ACCUM block. Activities may elect to increase the depth of inspection if equipment condition, visual external inspection, or record examination indicates such action is warranted. Aircraft transferred from a depot or commercial repair activity require hydraulic fluid sampling prior to transfer. On transfer of an aircraft, download the SEATS/ICAPS module data disk pertaining to the aircraft logbook. (not required for NTCSS Optimized OMA NALCOMIS activities).

NOTE: Activities deploying detachments, for example, HC or HSL, that transfer and accept aircraft between homeguard and detachment are not required to perform a physical transfer inspection or acceptance inspection. The administrative requirements, for example, configuration and AIR verification, OPNAV XRAY, and ETRs are still required.

117.3 Discuss the following elements of the Oil Consumption Program: [ref. d, ch. 9]

a. Program manager shall:

(1) Be knowledgeable of applicable MIMs, MRCs, and this instruction.

(2) Provide indoctrination and follow-on training to personnel relating to their Oil Consumption Program responsibilities.

(3) Maintain a program file to include:

(a) Applicable POCs.

(b) Program related correspondence and message traffic.

(c) Applicable references or cross reference locator sheets.

(4) Use CSEC information and reports (provided by the Program Monitor) to identify specific areas of concern and to determine steps required for program/process improvement.

(5) Ensure grade and quantity of oil added to each engine is annotated in block 6 of the Aircraft Inspection and Acceptance Record (OPNAV 4790/141) per this instruction. Block 8 may be used to document gearbox oil, hydraulic fluid quantity, or other aircraft servicing information.

(6) Ensure aircraft releasing authorities verify oil consumption limits have not been exceeded, per applicable MIMs/MRCs, prior to releasing aircraft safe for flight.

(7) Ensure personnel assigned duties of servicing engines and gearboxes are trained on proper servicing techniques and documentation requirements.

(8) Ensure safe for flight certified personnel receive adverse oil consumption values/trends certification training as part of the qualification procedures for certification.

(9) Ensure oil consumption rates are calculated and documented prior to releasing aircraft safe for flight.

(10) Ensure an Engine/Gearbox Oil Consumption Record (Figure 9-1) is retained in the ADB until completed. Completed forms shall be placed with the applicable AESR and accompany the aircraft/engine when transferred. Gearbox oil consumption records can be disposed of locally after gearbox transfer. Figure 9-1 is a sample format. Commands are authorized to deviate from this format for unit specialization, ensuring required data elements are met. NOTE: Only current and most recently completed forms are required to be retained.

(11) Ensure appropriate action, per applicable MIMs, is taken when any consumption value or increase in consumption value exceeds the authorized limits.

(12) Ensure all pilots/aircrew taking aircraft on cross-country evolutions have been briefed on oil consumption/servicing procedures and responsibilities.

b. Consumption trends/limitations for your type/model/series aircraft

For Hornets, Read CSFWP/CSFWL APPENDIX E, NAMSOP CNAFINST 4790.2 VOL V. 21 JUN 06. The formula is following: EOT =EFH x 1.3. If old added exceeds 30 ounces or EFH exceeds 8.0 hours, calculate usage using the following Formula: oil added divided by (total EFH x 1.3) = usage rate. Limit is 24 ounces per engine operation time.

c. Documentation

1. Maintenance Control shall ensure:

(1) Oil consumption rates are calculated and documented for engines/gearboxes prior to releasing aircraft safe for flight.

(2) An Engine/Gearbox Oil Consumption Record (Figure 9-1) is retained in the ADB until completed. Completed forms shall be placed with the applicable AESR and accompany the aircraft/engine when transferred. Gearbox oil consumption records can be disposed of locally after gearbox transfer.

2. Program monitor shall: Screen oil consumption records weekly for completeness and accuracy with particular attention paid to abnormal trends and values that fall outside the authorized consumption limits.

.4 Discuss the scheduled removal components and assemblies applicable

to your type/model/series aircraft. [ref. a, ch. 13]

* Scheduled Removal Components and Assemblies

SRCs and assemblies with operating limitations are normally replaced at the scheduled inspection which falls nearest to the applicable limitation. To reduce replacements at other than scheduled inspections, a margin of plus or minus 10 percent of the stated operating limitations is authorized for components/assemblies, unless such extension is prohibited by the applicable PMIC or other directive. Components/assemblies requiring SRC cards/ASRs shall be inventoried during phased inspection for the applicable equipment being inspected. Activities with NTCSS Optimized OMA NALCOMIS shall verify all applicable PMICs against the CM Inventory Explorer. At the completion of one complete phased cycle all SRC/ASR and CM ALS items shall have been inventoried. The inventory is performed using a locally prepared form containing a preprinted list of SRC/ASR or CM ALS items with a column provided for recording the serial number of the installed items. On-condition items requiring EHRs or CM ALS items shall be included on this inventory list. This list will be reviewed to ensure installed components and assemblies requiring ASR, EHR, or CM ALS and SRC cards match the aircraft or AESR inventory record or CM Inventory Explorer.

NOTE: The 10 percent extension deviation is not authorized for structural life limited components (listed in NAVAIRINST 13120.1, NAVAIRINST 13130.1, and applicable PMICs) that have reached their basic life limitations or would reach those limitations during the extension.

  1. Outer Wing Section Assembly (Port) (SRC)
  2. Outer Wing Section Assembly (Stbd) (SRC)
  3. Inner Wing Section Assembly(Port) (SRC)
  4. Inner Wing Section Assembly (Stbd) (SRC)
  5. Rotary, Mechanical, Wingfold Transmission (Port) (EHR)
  6. Rotary, Mechanical, Wingfold Transmission (Stbd) (EHR)
  7. Canopy, F/A-18C Only (EHR)
  8. Windshield (After AFC-247) (EHR)
  9. Shank Assembly, Arresting Hook (SRC)

10. NLG Launch Bar Assembly (SRC)